POWER MODULE AND MANUFACTURING METHOD THEREOF
A power module and a manufacturing method are provided. The power module includes a first electronic assembly and a second electronic assembly. The first electronic assembly includes at least one pin. The second electronic assembly includes a first surface and a second surface opposite to each other. The first surface is more adjacent to the first electronic assembly than the second surface. A direction from the first surface toward the second surface is defined as a reference direction. The second electronic assembly includes a first region and a second region. The first region has a first thickness in the reference direction. The second region has a second thickness in the reference direction. The second thickness is less than the first thickness. The second region includes at least one through hole. The pin is penetrated through the at least one through hole and fixed on the second electronic assembly.
This application claims priority to China Patent Application No. 202210134656.7 filed on Feb. 14, 2022. The entire contents of the above-mentioned patent application are incorporated herein by reference for all purposes.
FIELD OF THE INVENTIONThe present disclosure relates to a power module and a manufacturing method of the power module, and more particularly to a power module having a circuit board with a groove and a manufacturing method of the power module.
BACKGROUND OF THE INVENTIONThe power module includes a substrate, a circuit board and a plurality of electronic components. The electronic components are disposed on the circuit board. The substrate and the circuit board are stacked with each other. The substrate and the circuit board are connected to each other by inserting the pins fixed on the substrate into the through holes of the circuit board. For enhancing the output power from the power module, the thickness of the circuit board of the power module is increased. Moreover, the pins of the substrate and the through holes of the circuit board of the power module are connected to each other by automation soldering, such as wave soldering or selective soldering. When the thickness of the circuit board of the conventional power module is increased, the filing efficiency of the solder filled in the through holes of the circuit board may reduce. Moreover, the residue of the solder such as tin bead or tin slag is easy to be produced after soldering. In addition, for achieving the miniaturization of the power module, the electronic components are disposed on the circuit board more closely, and the flash distance between the electronic components disposed on the circuit board is reduced. Consequently, the electronic components may short-circuited with each other easily when the soldering progress is proceeded. Under some circumstances, the pin of the substrate is soldered with its root to fix and electrically connect with the external circuit board. Consequently, the regular automation soldering equipment can't be employed and artificial soldering can only be utilized. The soldering efficiency of the conventional power module is reduced, and the manufacture time of the conventional power module is increased.
SUMMARY OF THE INVENTIONAn object of the present disclosure provides a power module and a manufacturing method of the power module. The power module and the manufacturing method of the power module have advantage of enhancing filling efficiency, enhancing soldering efficiency and enhancing product yield.
In accordance with an aspect of the present disclosure, a power module is provided. The power module includes a first electronic assembly and a second electronic assembly. The first electronic assembly includes at least one pin. The second electronic assembly includes a first surface and a second surface opposite to each other. The first surface is more adjacent to the first electronic assembly than the second surface. A direction from the first surface toward the second surface is defined as a reference direction. The second electronic assembly further includes a first region and a second region. The first region has a first thickness in the reference direction. The second region has a second thickness in the reference direction. The second thickness is less than the first thickness. The second region includes at least one through hole. The at least one pin is penetrated through the at least one through hole and fixed on the second electronic assembly.
In accordance with another aspect of the present disclosure, a manufacturing method of a power module is provided. Firstly, a first electronic assembly is provided. The first electronic assembly includes at least one pin. Then, a second electronic assembly is provided. The second electronic assembly includes a first region and a second region. The second region includes at least one soldering pad and at least one through hole. A position of the at least one soldering pad is corresponding to a position of the at least one through hole. A second thickness of the second region is less than a first thickness of the first region. The at least one pin is penetrated though the at least one through hole from a first surface of the second region and fixed on the at least one soldering pad located on a second surface of the second region. Then, the first electronic assembly and the second electronic assembly are preheated. Then, a solder is provided on the second surface of the second electronic assembly, and at least portion of the solder is disposed around the at least one pin. Finally, the solder is partially heated so as to fix the at least one pin on the second electronic assembly and electrically connect with the at least one soldering pad.
The above contents of the present disclosure will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which:
The present disclosure will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this disclosure are presented herein for purpose of illustration and description only. It is not intended to be exhaustive or to be limited to the precise form disclosed.
Preferably but not exclusively, the substrate 2 includes a heat-dissipating substrate to dissipate the heat of the power module 1. The substrate 2 includes a first surface 21 and a second surface 22. The first surface 21 and the second surface 22 of the substrate 2 are opposite to each other. Each of the plurality of pins 3 includes a first end 31 and a second end 32. The second end 32 of each of the plurality of pins 3 is disposed and fixed on the substrate 2. In some embodiments, the second end 32 of each of the plurality of pins 3 is protruded from the second surface 22 and disposed on the substrate 2. The first end 31 of each of the plurality of pins 3 is extended away the substrate 2. In this embodiment, the plurality of pins 3 and the substrate 2 are connected to each other by utilizing the riveted joint. For simplifying the figures, in
As shown in
In this embodiment, the direction from the first surface 41 toward the second surface 42 of the first circuit board 4 is defined as a reference direction. The first circuit board 4 includes at least two regions based on different thicknesses in the reference direction. For example, the at least two regions include a first region and a second region. The first region is a region of the first circuit board 4 having complete plate without any groove. The first region has a first thickness in the reference direction. The second region is a region of the first circuit board 4 having the groove 44. The second region has a second thickness in the reference direction. The second thickness of the second region is less than the first thickness of the first region.
As shown in
Then, as shown in
Then, as shown in
As shown in
From above, the depth H1 of the first through hole 43 (i.e., the second thickness of the second region of the first circuit board 4) of the power module 1 of the present disclosure is less than the thickness H2 of the first circuit board 4 (i.e., the first thickness of the first region of the first circuit board 4). The pin 3 is penetrated through the first circuit board 4 through the first through hole 43. Portion of the solder 5 is disposed in the gap between the inner lateral surface of the first through hole 43 and the pin 3, and other portion of the solder 5 is protruded from the first surface 41 and the second surface 42 of the first circuit board 4. Consequently, the depth H1 of the first through hole 43 of the power module 1 of the present disclosure is decreased so as to reduce the heat dissipation of filling the solder 5 in the gap between the inner lateral surface of the first through hole 43 and the pin 3. In other words, the heat generated from the soldering region of the first circuit board 4 for the solder 5 is increased, so that the solder 5 is capable of being filled into the gap between the inner lateral surface of the first through hole 43 and the pin 3 easily. Consequently, the filling rate and the soldering efficiency of the solder 5 are enhanced. The residue of the solder 5 is not easy to be produced. The soldering quality and the soldering efficiency are enhanced. Moreover, the power module 1 of the present disclosure utilizes the local heating welding method to dispose portion of the solder 5 in the gap between the inner lateral surface of the first through hole 43 and the pin 3 and dispose another portion of the solder 5 on the soldering pad 45 located on the second surface 42 of the first circuit board 4. Furthermore, the other portion of the solder 5 is protruded from the first surface 41 of the first circuit board 4. Consequently, the automatic soldering process for the electronic components having shorter flash distance or electronic components required to be soldered with its root can be achieved. The problem of dropping and shifting of the other electronic components during soldering can be avoided. The electronic components are not short-circuited with each other. Consequently, the production efficiency and the product yield of the power module 1 of the present disclosure are enhanced.
In some embodiments, the substrate 2 includes a second through hole (not shown). Preferably but not exclusively, the second end 32 of the pin 3 is penetrated though the substrate 2 through the corresponding second through hole, and then the second end 32 of the pin 3 is connected to the substrate 2 by utilizing the riveted joint or SMT soldering, but is not limited thereto. The groove 44 is formed on the first surface 41 of the first circuit board 4, and then the first end 31 of the pin 3 is penetrated though the first circuit board 4 through the corresponding first through hole 43 to connect with the first circuit board 4 by above-mentioned connection method. In an embodiment, the pin 3 and the substrate 2 are integrally formed into one piece.
In some embodiments, the substrate 2 may include no heat-dissipating substrate.
In some embodiments, the solder 5 includes the solder paste. For controlling the consumption of the solder 5, preferably but not exclusively, the solder 5 includes the tin ring or the tin wire.
From the above descriptions, the present disclosure provides a power module. The depth of the first through hole of the power module of the present disclosure is less than the thickness of the first circuit board. The pin is penetrated through the first circuit board through the first through hole. Portion of the solder is disposed in the gap between the inner lateral surface of the first through hole and the pin, and another portion of the solder is disposed on the soldering pad located on the second surface of the first circuit board. Moreover, portion of the solder is protruded from the first surface of the first circuit board. Consequently, the depth of the first through hole of the power module of the present disclosure is decreased so as to reduce the heat dissipation of filling the solder in the gap between the inner lateral surface of the first through hole and the pin. In other words, the heat of the solder generated from the soldering region of the first circuit board is increased so as to fill the gap between the inner lateral surface of the first through hole and the pin easily. Consequently, the filling rate and the soldering efficiency of the solder are enhanced. The residue of the solder is not easy to be produced. The soldering quality and the soldering efficiency are enhanced. Moreover, the power module of the present disclosure utilizes the local heating welding method so that the automatic soldering process for the electronic components having shorter flash distance or electronic components required to be soldered with its root can be achieved. The rest solder points of the electronic components of the power module will not be heated to be soldered. Consequently, the problem of dropping and shifting of the electronic components during soldering can be avoided. The electronic components are not short-circuited with each other. Consequently, the production efficiency and the production yield of the power module of the present disclosure are enhanced.
While the disclosure has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure needs not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.
Claims
1. A power module, comprising:
- a first electronic assembly comprising at least one pin; and
- a second electronic assembly comprising a first surface and a second surface opposite to each other, wherein the first surface is more adjacent to the first electronic assembly than the second surface, and a direction from the first surface toward the second surface is defined as a reference direction, wherein the second electronic assembly further comprises: a first region having a first thickness in the reference direction; and a second region having a second thickness in the reference direction, wherein the second thickness is less than the first thickness, the second region comprises at least one through hole, and the at least one pin is penetrated through the at least one through hole and fixed on the second electronic assembly.
2. The power module according to claim 1, wherein the first electronic assembly or the second electronic assembly comprises at least one soldering pad, a position of the at least one soldering pad is corresponding to a position of the at least one through hole, and the at least one soldering pad is disposed on the first electronic assembly or the second surface of the second electronic assembly.
3. The power module according to claim 1, wherein the first electronic assembly comprises a heat-dissipating substrate, and the second electronic assembly comprises a circuit board.
4. The power module according to claim 1, wherein the first electronic assembly and the second electronic assembly respectively comprise a circuit board.
5. The power module according to claim 1, wherein the first thickness is greater than or equal to 2 mm.
6. The power module according to claim 4, wherein the second thickness is between 1 mm to 1.8 mm.
7. The power module according to claim 1, wherein the first region and the second region are coplanar with each other in the second surface of the second electronic assembly, and the first region and the second region are not coplanar with each other in the first surface of the second electronic assembly.
8. The power module according to claim 1, wherein the first region and the second region are not coplanar with each other in the second surface of the second electronic assembly, and the first region and the second region are not coplanar with each other in the first surface of the second electronic assembly.
9. The power module according to claim 1, wherein a solder is partial heated to fix the at least one pin on the first electronic assembly or the second electronic assembly, or both of the first electronic assembly and the second electronic assembly.
10. The power module according to claim 9, wherein the solder comprises a tin wire, a tin ring or a solder paste.
11. The power module according to claim 10, wherein the solder is disposed on the second surface of the second electronic assembly, and at least portion of the solder is disposed partially around the at least one pin.
12. The power module according to claim 10, wherein the solder is filled in a gap between an inner lateral surface of the at least one through hole and the at least one pin.
13. The power module according to claim 9, wherein the solder is partial heated by laser welding.
14. A manufacturing method of a power module, comprising the steps of:
- (a) providing a first electronic assembly, wherein the first electronic assembly comprises at least one pin;
- (b) providing a second electronic assembly, wherein the second electronic assembly comprises a first region and a second region, the second region comprises at least one soldering pad and at least one through hole, a position of the at least one soldering pad is corresponding to a position of the at least one through hole, wherein a second thickness of the second region is less than a first thickness of the first region, and the at least one pin is penetrated though the at least one through hole from a first surface of the second region and fixed on the at least one soldering pad located on a second surface of the second region;
- (c) preheating the first electronic assembly and the second electronic assembly;
- (d) providing a solder on the second surface of the second electronic assembly, wherein at least portion of the solder is disposed around the at least one pin; and
- (e) partially heating the at least one solder so as to fix the at least one pin on the second electronic assembly and electrically connect the at least one pin with the at least one soldering pad.
Type: Application
Filed: Jan 12, 2023
Publication Date: Aug 17, 2023
Inventors: Jianxin Chen (Shanghai), Kun Jiang (Shanghai), Quansong Luo (Shanghai)
Application Number: 18/096,356